Hidden fastener guard rail system

ABSTRACT

A guard rail system available in kits ready for assembly is formed of a capped wood composite with the look and feel of wood. The system includes balusters fastened to an upper rail and a bottom rail, each of which are attached to a post or wall. The upper rail is formed of a plurality of pieces that fit together to form a circumferential finished surface and include a longitudinal cavity. Fasteners that couple the balusters to the upper rail and the upper rail to the posts, are not externally visible. The brackets that couple the upper rail to the posts are disposed within the longitudinal cavity.

FIELD OF THE INVENTION

This invention relates to guard rail systems. In particular, this invention relates to a prefabricated guard rail system, components for a guard rail system and kits of components for a guard rail system that meets building code requirements.

BACKGROUND

Guard rails are used around decks, balconies, platforms, staircases and other elevated structures, to prevent injury and possible death from falling off of the edge of such structures. Most building codes have rigid requirements for guard rails, both in terms of where they are required and also prescribing certain construction parameters.

There is a need for deck and porch railing products that offer the look and feel of wood, provide a maintenance-free finish, are easily and quickly installed, have minimal numbers of parts including pieces and hardware, and which meet building code requirements as above.

Guard rail systems formed of wood, wood composites, various vinyl materials, and capped wood composites are available. Guard rail systems formed of capped wood composites are available in kits for easy installation whereas guard rail systems formed of wood or wood composites are fabricated at the job site and assembled using conventional wood practices, i.e., using screws and nails as fasteners. The fasteners used to assemble such railing systems are typically exposed, i.e., screw/nail heads are visible and aesthetically displeasing. Some vinyl guard rail systems such as PVC (polyvinyl chloride) systems are provided in kits, include pre-drilled holes and are easily assembled. A shortcoming of most vinyl systems, however, is that unsightly exposed metal brackets are typically used to secure the components of the guard rail system together.

While PVC systems generally offer the advantage of kits, additional parts and pieces are also required to address installation concerns presented by angles and stairs which requires the manufacture of application specific components. Some PVC systems also use injection molded sleeves to hide the rail-to-post bracket connection. While the sleeves are generally effective at masking this connection, the sleeves and screws exposed to secure the sleeve to the rail detract from the appearance of the rail. Other PVC systems use routed slot-joint type systems to eliminate exposed fasteners, yet these components are prone to rattle and require numerous components with specific routing patterns to address various installation conditions, e.g. line post, corner post, end post, stair end post, stair thru post, and left and right stair to guard rail corners. Moreover, when grasped, hollow PVC over metal reinforcement rails feel hollow or plastic emphasizing the fact that the rail system is not formed of wood.

Capped wood composite guard rail systems offer the advantage of being provided in kits yet also having the appearance and feel of wood. Systems having the appearance of wood are typically favored in the guard rail industry. Current capped wood guard rail systems require metal brackets to connect the rails to the posts. The metal brackets are typically fastened below the rail, remaining undesirably visible in the finished assembly and revealing that the guard rail system is not formed of wood.

It would therefore be desirable to provide a guard rail system that has the look and feel of wood, yet is formed of materials that can be provided in kits for easy assembly, and which further include hidden fasteners not visible to the exterior.

SUMMARY OF THE INVENTION

To address these and other needs, and in view of its purposes, the present invention provides a guard rail system formed of various materials and which may be pre-cut in kits, including capped wood composite materials that give the appearance of wood. The system includes hidden fasteners and brackets that eliminate unsightly screw or nail heads and which undesirably reveal that the system is not made of wood.

According to one aspect of the invention, provided is a guard rail system that includes an upper rail and a bottom rail affixed to at least two anchor members and a plurality of balusters affixed to the upper rail and lower rail. The upper rail comprises a plurality of cooperating longitudinal members and includes a longitudinal cavity therein. First fasteners that fasten the upper rail to the balusters are not externally visible and the upper rail is affixed to each of the anchor members by a bracket disposed completely within the longitudinal cavity and not externally visible. The anchor member may be a post or wall or other structure to which a rail may be attached or anchored.

In another aspect of the invention, provided is a guard rail system that includes an upper rail and a bottom rail affixed to at least two anchor members and a plurality of balusters affixed to the upper rail and lower rail. The upper rail comprises a handrail superjacently joined to a top universal rail with a longitudinal cavity therebetween. First fasteners that fasten the upper rail to the balusters are not externally visible and the upper rail is affixed to each of the anchor members by a bracket disposed completely within the longitudinal cavity and not externally visible. The top universal rail has a cross-sectional shape of an upright U and is affixed to the balusters.

In another aspect of the invention, provided is prepared kit for a guard rail system comprising an upper rail and a lower rail adapted to be coupled to at least two anchor members, a plurality of balusters adapted to be coupled to the upper rail and the lower rail, each baluster including a bore for receiving a fastener. The upper rail comprises a handrail and a top universal rail to be joined together, the handrail over the top universal rail, to form a longitudinal cavity therebetween. First fasteners that fasten the top universal rail to the balusters are not externally visible. Brackets that affix the upper rail to each of the anchor members are disposed completely within the longitudinal cavity and not externally visible.

BRIEF DESCRIPTION OF THE DRAWING

The present invention is best understood from the following detailed description when read in conjunction with the accompanying drawing. Like numerals denote like features throughout the specification and drawing.

FIG. 1 is a cross-sectional side view of an exemplary guard rail system of the invention;

FIG. 2 is a perspective view of a portion of the guard rail system of the invention including the hidden fastener;

FIG. 3 is a perspective view of an exemplary fastener used in the guard rail system of the invention;

FIG. 4 is a cross-sectional perspective view of an exemplary guard rail system of the invention; and

FIGS. 5 and 6 are cross-sectional end views showing other exemplary embodiments of the guard rail system of the invention.

DETAILED DESCRIPTION

The present invention provides a guard rail system formed of various materials. The components may be formed of vinyl materials such as PVC, wood composites, or capped wood composites which may include a white or colored capstock over a wood composite core to produce a painted look. The finish of the external surfaces used for the upper rail, bottom rail, balusters, and post sleeve may be a wood grain finish that provides the look and feel of wood. The systems may come in kits which are pre-cut and may include pre-drilled holes for assembly. In one embodiment, any or all of the balusters, post sleeve, upper and lower rail components may be formed of a polymer wood composite such as a foamed polymer-fiber composite such as described in U.S. Pat. No. 6,344,268, issued to the present inventor as one of multiple inventors. The building materials described in U.S. Pat. No. 6,344,268 include, in one embodiment, a foamed polymer composite building material consisting of about 35-73 wt. % polyvinyl chloride (PVC) resin, about 27-65 wt. % fiber, a specific gravity of about 1.07 g/cc or less, and including a porosity of at least 1%. This exemplary foam polymer composite building material is capable of having a screw fastener countersunk therein without pre-drilling. U.S. Pat. No. 6,344,268 is hereby incorporated by reference, as it set forth in its entirety and the aforedescribed exemplary building material and the other building materials disclosed in U.S. Pat. No. 6,344,268 may be used as building materials of the present invention in various embodiments.

An aspect of the present invention is that the guard rail system provides an aesthetically pleasing wood grain finish combined with hidden fasteners.

FIG. 1 is a cross-sectional side view looking longitudinally along an exemplary guard rail system. The guard rail system consists of a plurality of balusters, such as baluster 7, coupled to upper rail 1 and lower rail 3 which are in turn coupled to a plurality of anchor members such as post 5 having post sleeve 41 and post cap/ring 43. Post sleeve 41 is preferably a hollow sleeve that is used over a wood 4×4 or metal post secured to a deck, porch, platform, or other patio surface or frame. The aforementioned components may each be of various different sizes as determined by application, in other exemplary embodiments. Also, in other exemplary embodiments, the anchor member may be a wall or other structure fixedly secured to the ground or another surface and it may include a round cross-section or other curved surfaces.

In the exemplary illustrated embodiment, upper rail 1 is formed of universal rail 13 and top (hand) rail 23 which are joined to produce upper rail 1 with upper longitudinal cavity 29. In the exemplary illustrated embodiment, top rail 23 includes longitudinal cavity 49 but as will be shown in subsequent figures, this is intended to be exemplary only. Top rail 23 may optionally include one or more flanges 67 that assist in the alignment or positioning of top rail 23 on upper universal rail 13. Upper universal rail 13 is generally U-shaped as assembled and optionally includes at least one flange 17 to aid in aligning baluster 7 to upper rail 1, specifically to upper universal rail 13. Lower universal rail 15 also includes optional flange 19 for aligning baluster 7 to lower universal rail 15. In one embodiment, bottom rail 3 is formed of universal rail 15 and optional base rail 25 that covers lower longitudinal cavity 31 that extends below balusters 7. Both upper and lower universal rails 13 and 15 include bore 37, indicated by dashed lines, that is aligned with corresponding bore 39, also indicated by dash lines, formed in baluster 7. A fastener that secures upper universal rail 13 to baluster 7 extends down from surface 51 and into bores 37 and 39. Such a fastener may include head 53 which may be countersunk within surface 51 or may rest above it. In either event, it should be pointed out that when top rail 23 is in position over upper universal rail 13, heads 53 of the fasteners used to couple upper universal rail 13 to baluster 7, are not externally visible. In other exemplary embodiments, other fastening means such as various suitable adhesives may be used to secure upper universal rail 13 to baluster 7. The bottom portion of upper universal rail 13 may include slots, holes or other recesses to receive the tops of balusters 7. Balusters 7 may be post-shaped, as illustrated in FIG. 3, or they may take on other shapes such as sheets or plates that are narrow or lengthy in the longitudinal direction. In various embodiments, balusters 7 may be glass or polymer plates or sheets that are 4-5″ or longer in length, but other baluster shapes and materials may be used in other exemplary embodiments.

Top rail 23 may be joined to universal rail 13 by various means. In one exemplary embodiment, conventional screws or other fasteners may be used. In one exemplary embodiment, an adhesive such as an epoxy may be used. In yet another exemplary embodiment, top rail 23 may be snap-fit into upper universal rail 13 using conventional techniques using slideable surfaces and cooperating flanges. Top rail 23 may be coupled to upper universal rail 13 by means of a flange or rib of top rail 23 secured below a corresponding flange or rib of upper universal rail 13. In yet another embodiment, top rail 23 may be secured to upper universal rail 13 by a screw driven upwardly in from the bottom of universal rail 13, and preferably countersunk within upper universal 13.

According to the embodiment in which bottom rail 3 is formed of lower universal rail 15 and optional base rail 25, the same techniques for joining the base rail, the universal rail, and the balusters, may be used. For example, lower universal rail 15 may be fastened to baluster 7 using the same fastening techniques, and cooperating bores 37 and 39, as described in conjunction with upper rail 1. Optional crushed block 65 provides support for the rail system between the anchors.

The fastener used to couple both upper rail 1 and lower rail 3, to post 5 or post sleeve 41, is contained within longitudinal cavities 29 and 31, respectively in the illustrated embodiment of FIG. 1. An L-shaped bracket may advantageously be used. With respect to upper rail 1, the bracket is therefore not externally visible and with respect to bottom rail 3, the bracket is also not externally visible when optional base rail 25 is used. The short face of generally L-shaped bracket 55 is shown in each of longitudinal cavities 29 and 31.

FIG. 2 is a perspective view showing bracket 55 that includes long face 57 and short face 59 and is generally L-shaped. Short face 59 includes opening 53 to receive the head of a fastener therein. Long face 57 includes openings such as holes 43. Openings 53 and 43 may optionally be beveled to accommodate fasteners such as flat head screws. Short face 59 is designed to be shorter than the corresponding depth of the cavity trench in which bracket 55 will be disposed and used to couple the rail to the post.

FIG. 3 shows bracket 55 disposed with an upper longitudinal cavity 29 of upper universal rail 13. It can be seen that fasteners 45 secure upper universal rail 13 to balusters 7 and according to embodiments in which the material used to form upper universal rail 13 is a foamed polymer-fiber composite, fastener 45 may be countersunk within surface 51 without pre-drilling. In other exemplary embodiments, fasteners 45 may not be countersunk within upper universal rail 13. Bracket 55 includes holes 43 that receive fastening members 61 that fasten bracket 55 to upper universal rail 13 and also hole 43A that receives a fastener that additionally fastens upper universal rail 13 to baluster 7. Short face 59 of bracket 55 includes opening 53. Upper universal rail 13 is coupled to post 5 by lag bolt 63 that is received in opening 53 of bracket 55 and extends into post sleeve 41 and post 5. In other embodiments, lag bolt 63 may extend only into post 5 when there is no post sleeve 41, or only into post sleeve 41. Fastening members other than lag bolt 63 may be used to join bracket 55 to post 5/post sleeve 41 in other exemplary embodiments. It should be noted that FIG. 3 shows the arrangement prior to the installation of top rail 23 over upper universal rail 13 which closes upper longitudinal cavity 29 and renders the fastening components shown in FIG. 3 in upper longitudinal cavity 29, hidden from the exterior. The same arrangement may be used in securing lower universal rail 15 to post 5. Furthermore, each of upper rail 1 and lower rail 3 may be secured to a plurality of posts 1 with a similar arrangement. If optional base rail 25 is not used, lower longitudinal cavity 31 serves as a trench extending upwardly from a bottom surface of lower universal rail 15. FIGS. 1 and 3 show that bracket 55 does not extend outside the trench and therefore bracket 55 is not visible from above or laterally, according to embodiments in which optional base rail 25 is not used.

FIG. 4 is a perspective view showing a cut away portion of a partially assembled guard rail section and illustrates baluster 7, post 5, bottom rail 3, and upper rail 1 formed of upper universal rail 13 and top rail 23. Upper longitudinal cavity 29 and any fastening members that extend within upper longitudinal cavity 29, are not externally visible. Fastening members used to join bottom rail 3 to post 5 and baluster 7 do not extend outside lower longitudinal cavity 31 and are not visible laterally or from above.

FIGS. 5 and 6 each illustrate another exemplary embodiment of the guard rail system of the invention. In particular, it can be seen that top rail 23 takes on different shapes in the illustrated exemplary embodiments of FIGS. 1, 5 and 6. For example, top rail 23 may be curved or it may be substantially flat or planar, or take on a variety of geometric shapes which may include bevels and edges as desired, for aesthetic purposes. In FIGS. 5 and 6, top rail 23 does not include cavity 49 included in top rail 23 shown in FIG. 1 and in FIG. 5, top rail 23 includes longitudinal rib 71 that extends into upper longitudinal cavity 29. It should be understood that various other configurations may be used in other exemplary embodiments. Longitudinal rib 71 may, for example, provide additional surfaces such as the sides of longitudinal rib 71 which may fit snugly in upper longitudinal cavity 29, and to which adhesives may be applied to join top rail 23 to universal rail 13.

The preceding merely illustrates the principles of the invention. It will thus be appreciated that those skilled in the art will be able to devise various arrangements which, although not explicitly described or shown herein, embody the principles of the invention and are included within its spirit and scope. Furthermore, all examples and conditional language recited herein are principally intended expressly to be only for pedagogical purposes and to aid the reader in understanding the principles of the invention and the concepts contributed by the inventors to furthering the art, and are to be construed as being without limitation to such specifically recited examples and conditions. Moreover, all statements herein reciting principles, aspects, and embodiments of the invention, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents and equivalents developed in the future, i.e., any elements developed that perform the same function, regardless of structure.

In the description, relative terms such as “lower,” “upper,” “horizontal,” “vertical,”, “above,” “below,” “up,” “down,” “top” and “bottom” as well as derivatives thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description and do not require that the apparatus be constructed or operated in a particular orientation. Terms concerning attachments, coupling and the like, such as “connected” and “interconnected,” refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise.

Although the invention has been described in terms of exemplary embodiments, it is not limited thereto. Rather, the appended claims should be construed broadly, to include other variants and embodiments of the invention, which may be made by those skilled in the art without departing from the scope and range of equivalents of the invention. 

1. A guard rail system comprising: an upper rail and a lower rail, each affixed to at least two anchor members, each anchor member comprising a wall or a post, one or more balusters affixed to said upper rail and said lower rail, said upper rail comprising a plurality of cooperating longitudinal members and including a longitudinal cavity therein, wherein said upper rail is secured to said balusters without externally visible fasteners, and said upper rail is affixed to each of said anchor members by a bracket disposed completely within said longitudinal cavity and not externally visible.
 2. The guard rail system as in claim 1, wherein said upper rail comprises a handrail affixed over a top universal rail that is joined to said one or more balusters.
 3. The guard rail system as in claim 2, wherein said handrail is affixed to said top universal rail using fastening means not externally visible.
 4. The guard rail system as in claim 2, wherein said top universal rail has a cross-sectional shape of an upright U.
 5. The guard rail system as in claim 4, wherein said handrail snap-fits into said top universal rail.
 6. The guard rail system as in claim 4, wherein said handrail includes a longitudinal first flange that is engaged below a corresponding longitudinal second flange of said top universal rail to secure said handrail to said top universal rail.
 7. The guard rail system as in claim 2, wherein said handrail is affixed to said top universal rail by a screw having a head flush with a lower surface of said top universal rail.
 8. The guard rail system as in claim 2, wherein said handrail includes a surface with at least one of a beveled portion, a substantially flat portion, a curved portion and an edge.
 9. The guard rail system as in claim 1, wherein said upper rail has a circumferential finished surface.
 10. The guard rail system as in claim 1, wherein said balusters are affixed to said upper rail by a top fastener extending through one of said longitudinal members and into a corresponding upper bore formed in said baluster, and affixed to said lower rail by a bottom fastener extending through said lower rail and into a corresponding bottom bore formed in said baluster.
 11. The guard rail system as in claim 1, wherein said balusters are affixed to at least one of said upper rail and said lower rail by an adhesive.
 12. The guard rail system as in claim 1, wherein said lower rail comprises a base rail subjacently coupled to a lower universal rail and forming a bottom longitudinal cavity therebetween, fasteners that fasten said lower universal rail to said balusters are not externally visible, and said lower rail is affixed to each of said anchor members by a bracket disposed completely within said bottom longitudinal cavity.
 13. The guard rail system as in claim 1, wherein said bracket is L-shaped with holes for receiving fastening members extending therethrough, at least one of said holes being a first hole for receiving a first screw that extends through said first hole, through one of said cooperating longitudinal members and into a corresponding bore in one of said balusters.
 14. The guard rail system as in claim 1, wherein said upper rail, said lower rail, and said balusters are formed of vinyl material, a polymer wood composite or a capped wood composite.
 15. The guard rail system as in claim 1, wherein at least one of said upper rail, said lower rail, and said balusters have a surface with a wood grain finish.
 16. The guard rail system as in claim 1, wherein said one or more balusters comprise transparent sheets or panels of glass or polymer.
 17. The guard rail system as in claim 1, wherein at least one of said upper rail, said lower rail, and said balusters are formed of a foamed polymer composite building material.
 18. The guard rail system as in claim 17, wherein said building material is capable of having a screw countersunk therein without predrilling.
 19. The guard rail system as in claim 1, wherein said anchor member comprises a post and further comprising a post sleeve surrounding said post and wherein each of said brackets affixes said upper rail to said post through said post sleeve or to said post sleeve.
 20. The guard rail system as in claim 1, wherein said lower rail includes a lower universal rail affixed to said one or more balusters and including a longitudinal cavity extending upwardly from a bottom surface thereof, said lower universal rail affixed to each of said anchor members using a bracket that does not extend outside said longitudinal cavity.
 21. The guard rail system as in claim 1, wherein said lower rail is affixed to each of said anchor members by a fastener not visible from above or laterally.
 22. The guard rail system as in claim 1, wherein said upper rail is secured to said one or more balusters using first fasteners.
 23. A kit for a guard rail system comprising: an upper rail and a lower rail, each affixable to at least two anchor members, each anchor member comprising a wall or a post, one or more balusters adapted to be coupled to said upper rail and said lower rail, said upper rail comprising a handrail and a top universal rail to be joined together, said handrail over said top universal rail, to form a longitudinal cavity therebetween, fastening means for fastening said top universal rail to said balusters and which are not externally visible when said guard rail system is assembled, and brackets that affix said upper rail to each of said anchor members and which are disposed completely within said longitudinal cavity and not externally visible when said guard rail system is assembled.
 24. The kit for a guard rail system as in claim 23, wherein said top universal rail has a cross-sectional shape of an upright U when affixed to said one or more balusters.
 25. The kit for a guard rail system as in claim 23, wherein said handrail and said top universal rail cooperate to produce said upper rail having a finished surface including at least one of a beveled portion, a substantially flat portion, a curved portion and an edge.
 26. The kit for a guard rail system as in claim 20, wherein said upper rail, said lower rail, and said balusters are formed of a capped wood composite material.
 27. The kit for a guard rail system as in claim 23, wherein each of said balusters includes a bore for receiving a fastener therein.
 28. A guard rail system comprising: an upper rail and a lower rail each affixed to at least two anchor members, each anchor member comprising a wall or a post, one or more balusters affixed to said upper rail and said lower rail, said upper rail comprising a handrail superjacently joined to a top universal rail with a longitudinal cavity therebetween, wherein said upper rail is affixed to said balusters without externally visible fasteners, said upper rail is affixed to each of said anchor members by a bracket disposed completely within said longitudinal cavity and not externally visible, and said top universal rail has a cross-sectional shape of an upright U and is affixed to said balusters.
 29. The guard rail system as in claim 28, wherein said upper rail is affixed to said balusters by fasteners that extend through said top universal rail, and said balusters each include a bore that receives one of said fasteners therein.
 30. The guard rail system as in claim 28, wherein said upper rail, said bottom rail and said balusters are formed of a capped wood composite material and form a pre-prepared kit ready for assembly.
 31. The guard rail system as in claim 29, wherein said lower rail is affixed to each of said anchor members by a fastener not visible from above or laterally.
 32. The guard rail system as in claim 28, wherein said lower rail comprises a lower universal rail having a cross-sectional shape that is substantially the same as the cross-sectional shape of said top universal rail. 